This paper highlights the work undertaken at the CSIR on the issue of rapid die manufacturing through the application and evaluation of a rapid prototyping technique and coating technologies applied to die components of a high pressure casting die for the production of aluminium components. Criteria for determining suitability were developed against which the technique was evaluated that included time, cost and life-expectancy. Results of accelerated testing procedures to evaluate the die material produced by the rapid prototyping technique and surface coatings and treatments of die materials for their resistance to washout, erosion, heat checking and corrosion in a high pressure die casting environment, are presented. The outcomes of this research will be used for further development and application of specific technique, design principles and criteria for this approach